Augmented and mediated reality welding helmet systems

ABSTRACT

A welding helmet system is provided. The welding helmet system includes a protective shell and a welding display system. The welding display system is configured to be removably coupled to the protective shell. The welding display system is configured to receive data from a sensor, and to display a welding metric derived from the sensor via the image generation system.

RELATED APPLICATIONS

The present application is a continuation of, and claims priority to,co-pending U.S. patent application Ser. No. 17/726,905, entitled“AUGMENTED AND MEDIATED REALITY WELDING HELMET SYSTEMS,” having a filingdate of Apr. 22, 2022, which is a continuation of U.S. patentapplication Ser. No. 16/012,553, entitled “AUGMENTED AND MEDIATEDREALITY WELDING HELMET SYSTEMS,” having a filing date of Jun. 19, 2018,which is a continuation of U.S. patent application Ser. No. 14/561,770(now U.S. Pat. No. 10,032,388), entitled “AUGMENTED AND MEDIATED REALITYWELDING HELMET SYSTEMS,” filed Dec. 5, 2014, the entireties of which areall hereby incorporated by reference.

BACKGROUND

The present disclosure relates generally to welding helmet systems and,more particularly, to augmented and mediated reality welding helmetsystems.

Welding is a process that has increasingly become utilized in variousindustries and applications. Such processes may be automated in certaincontexts, although a large number of applications continue to exist formanual welding operations. In both cases, such welding operations relyon a variety of types of equipment to ensure the supply of weldingconsumables (e.g., wire feed, shielding gas, etc.) is provided to theweld in appropriate amounts at the desired time.

Welding operations are performed on a variety of different materialsusing various techniques. For example, a workpiece may be formed from acarbon steel, a corrosion resistant alloy, such as stainless steel, analuminum, and so on. Certain workpieces may thus benefit from differentwelding techniques and monitoring. Accordingly, a quality of a weld on aworkpiece may depend on more closely monitoring the welding operation.It would be beneficial to improve monitoring capabilities via weldinghelmet systems.

BRIEF DESCRIPTION

In one embodiment, a welding helmet system is provided. The weldinghelmet system includes a protective shell and a welding display system.The welding helmet system includes a protective shell and a weldingdisplay system. The welding display system is configured to be removablycoupled to the protective shell. The welding display system isconfigured to receive data from a sensor, and to display a weldingmetric derived from the sensor via the image generation system.

In another embodiment, a welding helmet system includes a protectiveshell, and a first welding display system configured to be removablycoupled to the protective shell. The first welding system is configuredto receive data from a sensor. The first welding system is additionallyconfigured to display a welding metric, wherein the welding metric isderived from the data, and to communicate with a second welding displaysystem, with an external system, or a combination thereof.

In a further embodiment, a welding display system is provided. Thewelding display system includes an image generation system and anattachment system configured to attach and to detach the welding displaysystem to a welding helmet, to a protective face shield, or acombination thereof. The welding display system includes a processorconfigured to receive data from a sensor, and to display the weldingmetric via the image generation system, wherein the welding metric isderived from the data.

DRAWINGS

These and other features, aspects, and advantages of the presentdisclosure will become better understood when the following detaileddescription is read with reference to the accompanying drawings in whichlike characters represent like parts throughout the drawings, wherein:

FIG. 1 is an illustration of an embodiment of a welding system includinga mediated reality welding helmet, in accordance with aspects of thepresent disclosure;

FIG. 2 is a cross-sectional side view of an embodiment of a weldinghelmet system having detachable augmented reality eyeglasses, inaccordance with aspects of the present disclosure;

FIG. 3 is a perspective view of an embodiment of the detachableaugmented reality eyeglasses of FIG. 2 , in accordance with aspects ofthe present disclosure;

FIG. 4 is a cross-sectional side view of an embodiment of a weldinghelmet system having detachable augmented reality eyeglasses, inaccordance with aspects of the present disclosure;

FIG. 5 is a perspective view of an embodiment of the detachableaugmented reality eyeglasses of FIG. 4 , in accordance with aspects ofthe present disclosure;

FIG. 6 is a front view of an embodiment of a protective shell includedin the welding helmet system of FIG. 4 , in accordance with aspects ofthe present disclosure;

FIG. 7 is a perspective view of an embodiment of a welding helmet systemhaving detachable augmented reality and mediated reality inserts, inaccordance with aspects of the present disclosure.

FIG. 8 is a front view of an embodiment of a face shield and AR/MRsafety glasses; and

FIG. 9 is a perspective view of an embodiment of a face shield and AR/MRsafety glasses of FIG. 8 .

DETAILED DESCRIPTION

Embodiments of the present disclosure may be used in any applicationwhere it may be desired to more closely monitor welding operations, forexample, via enhancements throughout a reality-virtuality continuum ofwelding and/or training operations. That is, the techniques describedherein may be applicable at a reality-only first end of the continuum,where the real environment is presented to a welding operator and/ortrainer unmodified, such as through a transparent or semi-transparentscreen. The techniques described herein may be further applicable toimprove welding operations and/or training by augmenting reality viaadditional features (e.g., augmented reality features) such as text,graphics, and/or audio superimposed onto the real environment. Thetechniques described herein may additionally improve welding operationsand/or training via a mediated reality, further along thereality-virtuality continuum, where reality may be mediated, forexample, by viewing the real world via one or more cameras. Further, thetechniques described herein may improve welding operations and/ortraining via presentation of a full virtual welding environment at anopposite end of the reality-virtuality continuum, where viewable andaudio constructs may all be computer generated. By operating throughoutthe entirety of the reality-virtuality continuum, the improvementsdisclosed herein may enhance and improve welding operations and weldingtraining.

Advantageously, the techniques described herein include removable,replaceable, and upgradeable inserts and eyeglasses that may be used inconjunction with welding helmets to provide for enhanced visualizationsand audible features. The inserts and eyeglasses described herein may becommunicatively coupled to a variety of sensors, welding power supplies,and external systems (e.g., cloud-based systems) to provide forvisualizations and audio useful in monitoring, for example, a quality ofwelding operations and/or training. The inserts and eyeglasses may becommunicatively coupled to each other to deliver, for example, visualand audio data to other interested parties, such as a supervisor ortrainer. Indeed, a variety of welding metrics, user biometrics, and/orenvironmental metrics may be derived and delivered via the inserts andeyeglasses described herein. It is to be understood that the termwelding metric, as described herein, includes images and videos taken bya camera sensor. By providing for a variety of reality-virtualitycontinuum inserts and eyeglasses, the techniques described hereinprovide for enhanced welding helmets suitable for more efficientlymonitoring welding operations.

Turning now to the figures, FIG. 1 illustrates an embodiment of an arcwelding system 10. As depicted, the arc welding system 10 may include apower supply 12 that generates and supplies welding power to anelectrode 14 via a conduit 16. In the arc welding system 10, a directcurrent (DC) or alternating current (AC) may be used along with aconsumable or non-consumable electrode 14 to deliver current to thepoint of welding. In such a welding system 10, an operator 18 maycontrol the location and operation of the electrode 14 by positioningthe electrode 14 and triggering the starting and stopping of the currentflow. As illustrated, a helmet system 20 is worn by the welding operator18. The helmet system 20 includes a helmet shell 22 and, in certainembodiments, a lens assembly that may be darkened to prevent or limitexposure to the light generated by a welding arc 26. The helmet system20 may be coupled to a variety of eyeglasses and inserts, as describedin more detail below, to provide for enhanced visuals and audio thatwork throughout the reality-virtuality continuum. The helmet shell 22and other protective shells described herein may be made of a variety ofmaterials, including carbon fiber, plastics, leather, fabric materials,or a combination thereof. The protective shells may protect againstheat, sparks, light, or a combination thereof.

When the operator 18 begins the welding operation (or other operationsuch as plasma cutting) by applying power from the power supply 12 tothe electrode 14, the welding arc 26 is developed between the electrode14 and a workpiece 28, such as the illustrated pipe. The workpiece 28may be formed from a carbon steel or a corrosion resistant alloy, suchas stainless steel, or other metals and alloys (e.g., aluminum,titanium, zirconium, niobium, tantalum, nickel alloys). Non-metal (e.g.,plastic, polymeric, rubber) workpieces 28 may also be welded orotherwise joined, for example, by stir welding.

Generally, the techniques described herein enable certain operations(e.g., welding, cutting, grinding, induction heating, testing) to beperformed on the workpiece 28 by applying power supplied by the powersupply 12. The workpiece 28 may be disposed in an industrial facility(e.g., industrial plant, shipyard) but may also be disposed in aresidential facility, such as a garage or a home. The workpiece 28 mayinclude tubular pieces (e.g., pipe), flat sheeting (e.g., metal orplastic sheets and plates), angled workpieces 28 (e.g., angle iron) orany other piece that may be welded, cut, ground, induction heated, ortested, for example, by using power delivered via the power supply 12.

The electrode 14 and the conduit 16 thus deliver current and voltagesufficient to create the welding arc 26 between the electrode 14 and theworkpiece 28. The welding arc 26 melts the metal (the base material andany filler material added) at the point of welding between the electrode14 and the workpiece 28, thereby providing a joint when the metal cools.The welding system 10 may be configured to form a weld joint by anysuitable technique, including shielded metal arc welding (SMAW) (i.e.,stick welding), gas tungsten arc welding (GTAW), gas metal arc welding(GMAW), flux-cored arc welding (FCAW), metal inert gas welding (MIG),tungsten inert gas welding (TIG), gas welding (e.g., oxyacetylenewelding), sub-arc welding (SAW), and/or resistance welding. As may beappreciated, shielding gas may be used in certain applications, such asGTAW, GMAW, and FCAW, for example. Waveforms used during welding mayinclude regulated metal deposition (RMD) type waveforms, among others,surface tension transfer (STT), cold metal transfer (CMT).

As mentioned above, the helmet system 20 may include a variety ofinserts and eyeglasses that provide for enhanced visualizations andaudio during welding operations and welding training. For example, FIG.2 illustrates an embodiment of the helmet system 20 including detachableaugmented reality (AR) safety eyeglasses 30 (e.g., welding displaysystem). The AR eyeglasses 30 may be securely coupled to a headgearassembly 32 via an eyeglass fastener 34 of the headgear assembly 32. Theheadgear assembly 32 may be adjustable to fit a variety of head 36 sizesand may be coupled to a protective welding helmet shell 38. For example,the headgear assembly 32 (e.g., helmet shell suspension system) mayattach to the helmet shell 38 via one or more attachment techniques(e.g., snap fasteners, rotating fasteners, screws, and the like).

In use, the welding operator 18 may attach the AR eyeglasses 30 to theheadgear assembly 32 via the eyeglass fastener 34, and then “flip down”the welding helmet shell 38 during welding (or training) activities. Afilter screen 40 on the welding helmet shell 38 may attenuate orotherwise filter light from, for example, the welding arc 26, to enablea more suitable view during the welding activities. The AR eyeglasses 30may include an image generation system 41 suitable for displaying imagesviewable by the operator 18, and/or a trainer, for example, as anoverlay over real world images viewable through the filter screen 40.More specifically, the image generation system 41 may includeprocessors, light projector systems, prisms, and so on, useful indelivering images viewable by the human eye. Accordingly, the realenvironment (e.g., viewable through the filter screen 40) may beaugmented via a variety of useful displays. For example, weldingmetrics, user biometrics, and/or environmental metrics may be providedas described in more detail below. By deriving and displaying a varietyof welding metrics, user biometrics, and/or environmental metrics,welding operations and training may be improved.

Sensors 39 may be communicatively coupled to the AR eyeglasses 30,directly or indirectly via another system (e.g., sensor data transmittedvia power supply 12), for example, through wireless protocols (e.g.,Bluetooth, IEEE 802.11x [e.g., WiFi], Zigbee, HART, LTE, Z-Wave,WirelessHD, WiGig). The sensors 39 may include sensors 39 disposed onthe power supply 12 (e.g., current and voltage sensors), on or about theworkpiece 28 (e.g., temperature sensors, optical sensors, x-raysensors), on the welding helmet shell 38, or on the AR eyeglasses 30themselves (for example to monitor the operator 18). When disposed onthe AR eyeglasses 30 and/or on (e.g., worn by) the operator 18, thesensors 39 may include biometric sensors suitable for deriving userbiometrics, for example, heat stress, heart rate (e.g., via pulseoximetry and the like), and other biometric readings of the operator 18.Accordingly, the operator 18 may be monitored, and data relayed to theoperator 18 (and third parties) relating to heat stress, heart rate, andthe like. Sensors 39 may additionally provide for derivations ofenvironmental metrics, such as surrounding temperature, humidity,ambient pressure, altitude, light levels, gases (e.g., air qualitygases), and the like. Indeed, the sensors 39 may include temperaturesensors, voltage sensors, current sensors, optical sensors, x-raysensors, capacitance sensors, inductive sensors, air quality sensors,and the like.

In certain embodiments, the AR eyeglasses 30 may include a camera 42(e.g., charge coupled device [CCD] sensor) and one or more speakers 44,as shown in FIG. 3 . More specifically, FIG. 3 shows a perspective viewof the AR eyeglasses 30 having a single camera 42 disposed betweenlenses 46. It is to be noted that, in other embodiments, one or morecameras 42 may be used, and the cameras 42 may be disposed at variouslocations, including a right temple 48 and/or a left temple 50 location.It is also to be noted that the lenses 46 may include prescriptionlenses suitable for adjusting or otherwise correcting vision, and thelenses 46 may be safety lenses suitable for use in industrialenvironments. Generally, the camera(s) 42 capture the same view as thatof the operator 18. The speakers 44 may include bone conduction speakerssuitable for conducting sound through bones in the human skull, in-earspeakers disposed inside the ear, over-ear speakers disposed on the ear,or a combination thereof.

In use, the camera(s) 42 may capture images and/or video of weldingoperations and/or training activities. The captured images and/or video(and all data captured, including sensor 39 data) may then be used, forexample, as logging data suitable for certifying a weld quality, and forfurther analysis. For example, a wired and/or wireless communicationssystem 52 may be used to transmit data to and receive data from externalsystems (e.g., power supply 12, cloud-based systems, local area network[LAN] workstations/servers, wide area network [WAN] workstation/servers,and so forth). The communications system 52 may include wireless systemssuch as 802.11x (e.g., WiFi), Zigbee, Z-wave, Bluetooth, cell phonecommunications systems (e.g., LTE, 4G, CDMA, GSM), and the like. Thecommunications system 52 may also include wired systems such as Ethernetbased systems, two-wire systems (e.g., I2C), PCI, 1-wire systems, andthe like.

The data transmitted from the AR eyeglasses 30 may include camera 42data, as well as data from other sensors 39 used to sense weldingoperations or training. Other sensor data may include temperature dataof the workpiece 28, power supply 12 data (e.g., voltage and currentused), workorder data (e.g., type of workpiece to be welded, type ofweld to be applied, welding supplies to be used), and so on. The data(e.g., camera 42 data and/or sensor 39 data) may be additionally oralternatively processed via processing circuitry 54. Attachment points56 may be used to attach the AR eyeglasses 30 to the eyeglass fastener34, and may additionally provide for electrically conductive attachmentsto provide power to charge batteries 58 that may power the AR eyeglasses30. For example, power may be provided via an external power supplyand/or via other batteries disposed on the welding helmet shell 38, andthe attachment points 56 may facilitate power being transferred fromsuch power sources to the AR eyeglasses 30. A user input system 60 maybe used by the operator 18 to provide a variety of inputs, such as viahead nods, eye winks, touch gestures (e.g., swipes of certain portionsthe temples 48, 50) and/or voice commands (e.g., via microphone). In oneexample, voice annotations during welding, as well as voice commands tochange voltage and/or current delivered via the power supply 12 may beprovided via the input system 60.

Camera 42 data (observing the weld torch 14) and/or sensors 39 may beprocessed to determine, for example, a welding speed, an angle at whichthe operator 18 holds the weld torch 14, as well as various weldobservations, which, depending on a type of weld (e.g., fillet weld,groove weld, lap weld, plug and slot weld) may includeconcavity/convexity metrics, cross sectional weld area, leg size, toeangle, undercut metrics, weld face metrics, weld throat metrics,mismatch metrics, bead width metrics, reinforcement height metrics,porosity metrics, and so on, which may be displayed via the imagegeneration system 41 in real-time during welding.

For example, weld speed may be determined by accelerometers on the weldtorch 14 and/or via camera 42/sensor 39 observations that identify theweld torch 14 moving with respect to the workpiece 28 or other object.Weld angle may be determined by similar visual observations via camera42/sensor 39 as well as via one or more gyroscopes disposed in the weldtorch 14. Visual observations via camera 42/sensor 39 may also observeif a weld is concave or convex, and measure concavity/convexitythickness, as well as the cross section of a weld area. Likewise, legsize, toe angle, undercut size/shape, weld face metrics, weld throatmetrics, mismatch metrics, reinforcement height (e.g., height of beadreinforcement), and/or bead width may be observed and measured, forexample, by applying trigonometric calculations. The cameras 42, 74and/or sensors 39 described herein may include a variety of sensorembodiments, including infrared sensors, x-rays, ultrasound, and thelike. Porosity, for example, may be measured via radiology and/orultrasound.

The camera 42 data processing (e.g., via external systems and/or via thecircuitry 54 of the AR eyeglasses 30) may include real-time processingsuitable for guiding the operator 18 during welding activities. Forexample, if the operator 18 is moving the electrode 14 too slowly or tooquickly, the AR eyeglasses 30 may then display, via the image generationsystem 41, certain animations, icons, warnings, text, and so on,notifying the operator 18 of the issue and/or corrective actions to take(e.g., slow down, speed up). The image generation system 41 mayadditionally display workorder information (e.g., type of workpiece 28,welding supplies to use, and so forth), further instructions, notes, andso on. Likewise, the speakers 44 may be used to provide audioindications, text-to-speech, and other audio suitable for improvingwelding operations, such as alarms, alerts, voice guidance, and thelike.

In one example, the operator 18 may scan a workorder (e.g., workorderbarcode) by using the camera(s) 42 and/or by using the input system 60.The AR eyeglasses 30 may then load certain parameters based on theworkorder, such as welding supplies to be used, type of weld to beperformed, and/or weld parameters (e.g., concavity/convexity metrics,cross sectional weld area, leg size, toe angle, undercut metrics, weldface metrics, weld throat metrics, mismatch metrics, bead width metrics,reinforcement height metrics, porosity metrics, and so forth). Theoperator 18 may then proceed with the welding operation, with thecamera(s) 42 capturing image data. The AR eyeglasses 30 may then use theinternal circuitry 54 and/or external systems to derive, via the imagedata and/or sensor data, a quality of welding. The AR eyeglasses maythen inform the operator 18 of the welding operation quality duringand/or after the welding operation. Data captured, such as image data,may be stored in a memory medium of the AR eyeglasses 30 and/or externalsystems (e.g., cloud storage), for example, to certify the weld or foradditional data analysis.

The AR eyeglasses 30 may be communicatively coupled to a second pair ofAR eyeglasses 30 worn by a supervisor or trainer. Accordingly, thesupervisor or trainer may don the second pair of AR eyeglasses 30 andobserve the welding or training activities in real-time. Pairing betweentwo or more AR eyeglasses 30 may be initiated by the third-partyobserver (e.g., supervisor), by the welding operator 18, and/or by the“cloud.” For example, the supervisor may don a pair of AR eyeglasses 30and may then request a list of other AR eyeglasses 30 that are online.In one embodiment, the list is filtered to only include AR eyeglasses 30located in a given facility or geographic area. The list mayadditionally be filtered to include only AR eyeglasses 30 that thesupervisor (or other entity) has access to. The supervisor may thenselect a desired pair of AR eyeglass 30 from the list. In oneembodiment, the supervisor may then enter additional securityinformation, such as login information, to complete the pairing and tobegin viewing data remotely. To unpair AR eyeglasses 30, either one ofthe supervisor or operator 18 may request to unpair and disconnect viathe input system 60, such as through voice command, menus, touches,gestures, and the like.

Voice and/or text feedback may be captured on the supervisor's inputsystem and transmitted to the operator 18 (and vice versa). Likewise,the AR eyeglasses 30 may be communicatively coupled to an externalsystem, such as a cell phone, tablet, computer, notebook, website,cloud-based system, and the like, which may be used by a third party toprovide feedback to the operator 18 when wearing the AR eyeglasses 30.Further, the AR eyeglasses 30 may display, via the image generationsystem 41, welding manuals, training videos, notes, and so on, useful tooperate and/or train on the welding system 10. Additionally, the AReyeglasses 30 may be communicatively coupled to other removable andreplaceable AR and/or mediated reality (MR) systems, as described in themore detail below.

FIG. 4 depicts an embodiment of the helmet system 20 having MReyeglasses 70 coupled to a protective welding shell 72. In the depictedembodiment, the MR eyeglasses 70 are coupled to the shell 72 viaheadgear assembly 32 and eyeglass fastener 34. Unlike the AR eyeglasses30 that may include transparent or semi-transparent lenses, the MReyeglasses 70 view data from an external camera(s) 74 mounted on anexterior face of the shell 72, and present the data to the operator 18and/or other users (e.g., supervisors, trainers). Accordingly, the MReyeglasses 70 can present data along the mediated portion of thereality-virtuality continuum because the MR eyeglasses 70 may mediatethe real environment via the camera(s) 74. For example, when the camera74 is in use, the MR eyeglasses 70 may display imaging data (e.g.,images, video) transmitted from the camera 74 representative of the realworld, thus providing for a mediated reality-based imaging.Additionally, the camera 74 data may be further processed, for example,by overlaying data (images, text, icons, and the like) on top of thecamera 74 images to further mediate reality, providing for a mediated ormixed reality view.

Further, the MR eyeglasses 70 may provide for an immersive virtualenvironment, where no camera 74 images are presented and instead, allimages are computer-generated in real-time. This virtual reality mode ofoperations may be particularly useful in training situations. Forexample, a virtual reality “world” may be presented, including virtualrepresentations of the workpiece 28, the power supply 12, the electrode14, and other components of the system 10. The operator 18 may thenvirtually weld the virtual workpiece 28 and receive feedback via the MReyeglasses 70 representative of weld quality during and/or after thevirtual welding operation. For example, the MR eyeglasses 70 mayinstruct the operator 18 to reposition the electrode 14, to change anangle of the electrode 14, to move the electrode 14 faster or slower, tochange power supply parameters (e.g., applying more or lesscurrent/voltage, and so on. Likewise, alerts, alarms, and other weldingparameters may be displayed. Additionally, third party users may providefeedback (voice, text) while viewing the operator's performance duringthe virtual welding, for example, through external systems such as cellphones, tablets, computers, notebooks, websites, cloud-based systems,through other AR eyeglasses 30, other MR eyeglasses 70, and the like.

In one embodiment, the virtual world may be created based on a scan of aworkorder, or via some other input. The virtual world may include avirtual representation of the type of material to be worked on, thewelding supplies to be used, the welding equipment (e.g., system 10) tobe used, and/or the work environment (e.g., upside down weld, flat weld,and so on). Accordingly, the operator 18 may train on a virtual worldrepresentative of the system 10 and workpiece 28 until a desired weldquality is achieved. The operator 18 may then switch to anaugmented-reality mode, a mediated-reality mode and/or a reality-onlymode, and proceed with performing the physical weld. In this manner, amore focused and efficient training environment may be provided, betterrepresenting the work about to be performed.

FIG. 4 additionally shows further details of a portion 76 of the shell72 showing an attachment assembly 78 of the shell 72 suitable forattaching the MR eyeglasses 70 when disposed inside of the shell 72. Inthe depicted embodiment, the MR eyeglasses 70 may include a frame 80that may be “slid” or otherwise disposed inside of the attachmentassembly 78. An interference fit or force, a magnetic force, aspring-bias force, or a combination thereof, may then provide for asecure attachment between the MR eyeglasses 70 and the shell 72 via theattachment assembly 78. Accordingly, movements of the head 36 may thencorrespondingly move the shell 72, cameras 74, and MR eyeglasses 70together, thus increasing view fidelity and minimizing view latency. Itis to be noted that, in other embodiments, the MR eyeglasses 70 may beused with shells 72 lacking the attachment assembly 78. It is also to benoted that the attachment assembly 78 may be used with the AR eyeglasses30 above as part of the shell 38, to more securely hold the AReyeglasses 30 in place when coupled to the shell 38.

FIG. 5 shows a perspective view of an embodiment of the MR eyeglasses70, showing certain features in more detail. Because FIG. 5 includeslike elements to the figures above, the like elements are shown withlike element numbers. It is also to be noted that elements of both theAR eyeglasses 30 and the MR eyeglasses 70 may be used in the othereyeglasses, such as input systems 60, 88, processing systems 54, 86, andthe like. In the depicted embodiment, the MR eyeglasses 70 include twodisplays 82. The displays 82 may include light emitting diode (LED)displays, organic LED (OLED) displays, liquid-crystal display (LCD)displays, or a combination thereof, suitable for displaying imagesand/or video. For example, the displays 82 may provide for a field ofvision (FOV) between 50 and 180 degrees horizontal at resolutionsbetween 800 to 8K horizontal and 800 to 8K vertical at desired aspectratios (e.g., 1:1, 5:4, 4:3, 3:3, 16:9, 16:10, and so on). Accordingly,an image generation system 84 may include circuitry suitable for drivingthe displays 82. In one example, a processing circuitry 86, for example,in combination with the image generation system 84, may drive images viathe displays 82 to achieve a latency (e.g., time between head movementsand corresponding movement of virtual embodiments displayed) of between125 Hz and 2000 Hz.

Indeed, an input system 88 may track head movement to derive a desiredviewing orientation, and thus change the data (e.g., virtual world) onthe displays 82 accordingly to match the viewing orientation. In thismanner, the operator 18 may more naturally move the head 36 with acorrelative change in the view presented by the displays 82. Also shownis a light blockage housing 90 suitable for minimizing or eliminatingexternal light sources impinging upon the displays 82, thus presentingmore generated light to the operator 18. It is to be noted that theeyeglasses 30 and 70 may be communicatively coupled to each other.Accordingly, the screens 82 may view imaging data (or other data)captured via the AR eyeglasses 30, and the AR eyeglasses 30 may displayimaging data (or other data) captured via the MR eyeglasses 70.

As mentioned earlier, the cameras 74 may capture imaging data forpresentation via the displays 82 and/or for transmission (e.g., viacommunications system 52) to external systems for data capture andfurther analysis, similar to the data capture and analysis describedabove with respect to the AR eyeglasses 30. Indeed, similar to the AReyeglasses 30, the camera 74 data may be processed to determine, forexample, a weld speed, an angle at which the operator 18 holds theelectrode 14, as well as various weld observations, which, depending ona type of weld (e.g., fillet weld, groove weld, lap weld, plug and slotweld) may include concavity/convexity metrics, cross sectional weldarea, leg size, toe angle, undercut metrics, weld face metrics, weldthroat metrics, mismatch metrics, bead width metrics, reinforcementheight metrics, porosity metrics, and so on, which may be displayed viathe image generation system 84 in real-time (and transmitted to externalsystems via system 52). The camera data processing (e.g., via externalsystems and/or via the internal circuitry 86) may include real-timeprocessing suitable for guiding the operator 18 during weldingactivities. For example, if the operator 18 is moving the electrode 14too slowly or too quickly, the MR eyeglasses 70 may derive or mayreceive derivations from external systems, to display, via the imagegeneration system 84 certain animations, icons, warnings, text, and soon, notifying the operator 18 of the issue and/or corrective actions totake (e.g., slow down, speed up). Likewise, the speakers 44 may be usedto provide audio indications suitable for improving welding operations,such as alarms, alerts, voice guidance, and the like.

Sensors 39 shown in FIGS. 4 and 5 may be communicatively coupled to theMR eyeglasses 70, directly or indirectly via another system (e.g.,sensor data transmitted via power supply 12) for example, throughwireless protocols (e.g., Bluetooth, IEEE 802.11x [e.g., WiFi], Zigbee,HART, LTE, Z-Wave, WirelessHD, WiGig). As mentioned above, the sensors39 may include sensors 39 disposed on the power supply 12 (e.g., currentand voltage sensors), on or about the workpiece 28 (e.g., temperaturesensors, optical sensors, x-ray sensors), on the welding helmet shell72, and on the MR eyeglasses 70 themselves (for example to monitor theoperator 18). When disposed on the MR eyeglasses 70 and/or on (e.g.,worn by) the operator 18, the sensors 39 may include biometric sensorssuitable for detecting, for example, heat stress, heart rate (e.g., viapulse oximetry and the like), and other biometric readings of theoperator 18. Accordingly, the operator 18 may be monitored, and datarelayed to the operator 18 (and third parties) relating to heat stress,heart rate, and the like.

As shown in FIG. 6 in a front view embodiment, the cameras 74 may beused in lieu of a filter screen, such as the filter screen 40. Thecameras 74 may communicate with the MR eyeglasses 70, for example, viawired conduits (e.g., High-Definition Multimedia Interface [HDMI],S-video, video graphics array [VGA], and so on), via wireless protocols,such as Wireless Display (WiDi), Wireless Home Digital Interface (WHDI),Bluetooth, IEEE 802.11x (e.g., WiFi), and so on). In certainembodiments, the cameras 74 may be affixed to the shell 72 via externalthreads disposed on a camera housing and corresponding internal threadsdisposed on the shell 72, or via other mechanical fastening techniques.In another embodiment, the cameras 74 may be magnetically attached tothe shell 72. Regardless of the fastening technique used, the cameras 74may be replaceable. Accordingly, the operator 18 may select cameras 74for specific operations. For example, higher magnification cameras(e.g., 2-20× magnification) may be selected to view smaller welds.Likewise, cameras having other optical characteristics, such as infraredor near infrared cameras may be used, which may additionally providetemperature data. In certain embodiments, the camera 74 types may bemixed. That is, one camera 74 may be a standard optical camera while asecond camera 74 may be an infrared camera.

It is also to be noted that the AR eyeglasses 30 and the MR eyeglasses70 may automatically switch into various operation modes (e.g., changefunctionality) based on, for example, where the eyeglasses 30 and 70 aredisposed. In one example, if the eyeglasses 30, 70 are disposed insideof the shells 38, 72, then certain user biometric derivations may becomputed, while eyeglasses 30, 70, not disposed in the shells 38, 72,may not derive the user biometrics unless specifically enabled by theuser. Likewise, the AR eyeglasses 30 and/or the MR eyeglasses 70 mayenable or disable certain functions based on the type of shells 38, 72that they may be disposed inside of. For example, the shell 38 enableslight to flow through screen 40, and thus, the AR eyeglasses 30 and/orMR eyeglasses 70 may enable modes that superimpose data over certainimages (e.g., images incoming through screen 40), while when disposed onthe shell 72, the AR eyeglasses 30 and/or MR eyeglasses 70 may enablemodes that display data over a larger portion or all of the lenses 42and/or displays 82. Accordingly, the AR eyeglasses 30 and the MReyeglasses 70 may automatically adapt to their surroundings.

FIG. 7 is a perspective view showing an embodiment of the helmet systemincluding an AR welding helmet 100, a detachable AR welding shield 102(e.g. welding display system), and a detachable MR welding shield 104.In use, the welding shield 102 or 104 may be coupled to the helmet 100,for example, to cover an integrated grind shield 106 and to provide forAR and/or MR features similar to those provided by the AR and MReyeglasses 30, 70. For example, in one AR embodiment, the detachablewelding shield 102 may include the image generation system 41 suitablefor displaying images viewable by the operator 18 and/or a trainer, asan overlay over real world images incoming through a filter screen 108.More specifically, the image generation system 41 may include projectorsystems, prisms, and so on, useful in delivering images viewable by thehuman eye through the filter screen 108.

In certain embodiments the image generation system 41 may additionallyor alternatively be disposed in a shell 110. Accordingly, the grindshield 106 may display the same or similar data as the AR eyeglasses 30and/or detachable AR welding shield 102. It is to be noted that all ofthe AR/MR systems 30, 70, 100, 102, 104 described herein may beuser-configurable. For example, the operator 18 may set up the AR/MRsystems 30, 70, 100, 102, 104 to show only certain types of data (e.g.,welding metrics, user biometrics, environmental metrics) and/or alertsand alarms. Accordingly, the AR helmet system 100 may be set up by theuser to only show data useful during grinding activities, while theAR/MR systems 30, 70, 102, 104 may be set up to show welding-relateddata.

The detachable AR welding shield 102 may include one or more cameras 42and the detachable MR welding shield 104 may include one or more cameras74. Likewise, the AR helmet 100 may include one or more cameras 42disposed at various locations on the shell 108 and/or the grind shield106. The cameras 42, 74, may be of the same type and may operate insimilar fashion as when mounted on the AR eyeglasses 30 and the MReyeglasses 70, respectively. That is, the cameras 42, 74 may captureimages and/or video of welding operations and/or training activities.The cameras 42, 74 (HD camera, SD camera, thermal camera, eddy currentcamera) The captured images and/or video may then be used, for example,as logging data suitable for certifying a weld quality, and for furtheranalysis. The cameras 74 (and 42), may be removable and repositionableon a shield surface 109 (e.g., via screw housings, magnetic housings,and the like), and may be communicatively coupled with the processingcircuitry 86 and image generation system 84 via wired or wirelessconduits (e.g., High-Definition Multimedia Interface [HDMI], S-video,video graphics array [VGA], and so on), via wireless protocols, such asWireless Display (WiDi), Wireless Home Digital Interface (WHDI),Bluetooth, IEEE 802.11x (e.g., WiFi), and so on).

As mentioned earlier, the cameras 42 may capture imaging data fortransmission to external systems (e.g., via communications system 52)for data capture and further analysis, similar to (or the same as) thedata capture and analysis described above with respect to the AReyeglasses 30. Likewise, the cameras 74 may be used for presentation ofimaging data via the display(s) 82 and/or may capture imaging data fortransmission to external systems (e.g., to other users), similar to thedata capture and analysis described above with respect to the MReyeglasses 70. Indeed, similar to the eyeglasses 30, 70, data from thecameras 42, 74 may be processed by the processing circuitry 54 and 86,respectively, or by external systems (e.g., power supply 12, cloud-basedsystems, local area network [LAN] workstations/servers, wide areanetwork [WAN] workstation/servers) to determine, for example, a weldspeed, an angle at which the operator 18 holds the electrode 14, as wellas various weld observations, which, depending on a type of weld (e.g.,fillet weld, groove weld, lap weld, plug and slot weld) may includeconcavity/convexity metrics, cross sectional weld area, leg size, toeangle, undercut metrics, weld face metrics, weld throat metrics,mismatch metrics, bead width metrics, reinforcement height metrics,porosity metrics, and so on, which may be displayed in real-time.

The camera data processing (e.g., via external systems and/or viainternal systems 54, 86) may include real-time processing suitable forguiding the operator 18 during welding activities. For example, if theoperator 18 is moving the electrode 14 too slowly or too quickly, thesystems 100, 102, 104 may derive or may receive derivations fromexternal systems to display, via circuitry 41 certain animations, icons,warnings, text, and so on, notifying the operator 18 of the issue and/orcorrective actions to take (e.g., slow down, speed up). Likewise, thespeakers 44 may be used to provide audio indications suitable forimproving welding operations, such as alarms, alerts, voice guidance,and the like.

The sensors 39 may be communicatively coupled to the systems 100, 102,104, directly or indirectly via another system (e.g., sensor datatransmitted via power supply 12) for example, through wireless protocols(e.g., Bluetooth, IEEE 802.11x [e.g., WiFi], Zigbee, HART, LTE, Z-Wave,WirelessHD, WiGig). As mentioned above, the sensors 39 may includesensors 39 disposed on the power supply 12 (e.g., current and voltagesensors), on or about the workpiece 28 (e.g., temperature sensors,optical sensors, x-ray sensors), on the systems 100, 102, 104,themselves (for example to monitor the operator 18). When disposed onthe systems 100, 102, 104, and/or on (e.g., worn by) the operator 18,the sensors 39 may include biometric sensors suitable for detecting, forexample, heat stress, heart rate (e.g., via pulse oximetry and thelike), and other biometric readings of the operator 18. Accordingly, theoperator 18 may be monitored, and data relayed to the operator 18 (andthird parties) relating to heat stress, heart rate, and the like.

Embodiments of the AR safety eyeglasses 30 and/or the MR safetyeyeglasses 70 (e.g., welding display systems 30, 70) may securelycoupled to a variety of protective equipment, including a protectiveface shield 120 (e.g., protective shell 120), shown in one embodiment inFIG. 8 . Indeed, when the protective face shield 120 is selected, theuser may then select the AR safety eyeglasses 30, the MR safetyeyeglasses 70, or other safety glasses, and position the selectedeyeglasses over the opening 122 to add enhanced protection. Variousfastening techniques may be used to fasten the AR safety eyeglasses 30and the MR safety eyeglasses 70 to the protective face shield 120. Forexample, an interference or friction fit between portions of the ARsafety eyeglasses 30 (or portions of the MR safety eyeglasses 70) andthe protective face shield 120 may securely couple the eyeglasses 30, 70to the protective face shield 120. Additionally or alternatively,latches, Velcro™, clips, and so on, may be used to secure the AR safetyeyeglasses 30 and the MR safety eyeglasses 70 to the protective faceshield 120.

It is to be noted that the protective face shield 120 may, in certainembodiments, include extra batteries 124 useful for providing additionalpower to the AR safety eyeglasses 30 and the MR safety eyeglasses 70.Indeed, the protective face shield 120 may be operatively coupled to theAR safety eyeglasses 30 and the MR safety eyeglasses 70 to provideeither extra electrical power via batteries 124 and/or extra processingpower via one or more processors 126. Accordingly, detachable electricalconnectors, such as magnetic connectors, pin-based connectors, and soon, may be used to electrically couple the protective face shield 120 tothe AR safety eyeglasses 30 and the MR safety eyeglasses 70.

Once the AR safety eyeglasses 30 or the MR safety eyeglasses 70 areaffixed onto the protective face shield 120, the entire assembly may bedonned by a user, such as the operator 18, for enhanced protection. Asshown in a perspective view embodiment of FIG. 9 , the AR safetyeyeglasses 30 and the MR safety eyeglasses 70 may include a strap 120,such as an elastic strap, suitable for securely holding the assembledeyeglasses 30, 70 and the protective face shield 120 to the operator 18.The operator 18 may then work on a desired task, and may more easilyswitch between the eyeglasses 30, 70, or other protective eyeglasses,when wearing the protective face shield 120. In this way, the operator18 may select eyeglasses, such as the eyeglasses 30, 70, more suitablefor a particular task, thus enhancing work efficiency, training, andsafety.

While only certain features of the present disclosure have beenillustrated and described herein, many modifications and changes willoccur to those skilled in the art. It is, therefore, to be understoodthat the appended claims are intended to cover all such modificationsand changes as fall within the true spirit of the present disclosure.

1. A welding display system, comprising: a coupler configured toremovably couple the welding display system to a protective shell; adisplay screen configured to display a welding metric, a user biometric,or an environmental metric; and a camera sensor positioned to captureimage data when the welding display system is coupled to the protectiveshell.
 2. The welding display system of claim 1, wherein the couplercomprises a fastener, a latch, or a clip.
 3. The welding display systemof claim 1, further comprising a processor configured to: receive theimage data from the camera sensor, derive a simulated weldingenvironment based on the image data, and display the simulated weldingenvironment on the display screen.
 4. The welding display system ofclaim 3, wherein the processor is configured to: derive one or moreparameters based on the image data captured by the camera sensor, andderive the simulated welding environment based on the one or moreparameters.
 5. The welding display system of claim 3, further includinga tracking system configured to track a movement of a head when thewelding display system is worn on the head.
 6. The welding displaysystem of claim 5, wherein the processor is configured to derive aviewing orientation based on the movement of the head tracked by thetracking system, and adjust the display of the simulated weldingenvironment on the display screen based on the viewing orientation. 7.The welding display system of claim 1, wherein the protective shellcomprises a welding helmet or a protective face shield.
 8. A weldinghelmet, comprising: a welding display system, comprising: a biometricsensor configured to detect user biometric data, and a display screenconfigured to display a user biometric derived from the user biometricdata.
 9. The welding helmet of claim 8, wherein the user biometriccomprises a user heat stress or a user heart rate.
 10. The weldinghelmet of claim 8, wherein the user biometric comprises a user heatstress.
 11. The welding helmet of claim 8, wherein the user biometriccomprises a user heart rate, the user heart rate being derived via pulseoximetry.
 12. The welding helmet of claim 8, wherein the welding helmetfurther comprises a protective shell, the welding display system beingpositioned within the protective shell.
 13. The welding helmet of claim12, wherein the welding display system further comprises a couplerconfigured to removably couple the welding display system to theprotective shell.
 14. The welding helmet of claim 12, wherein thecoupler comprises a fastener, a latch, or a clip, or the protectiveshell comprises a welding helmet or a protective face shield.
 15. Awelding helmet, comprising: a protective shell; and a welding displaysystem coupled to the protective shell, the welding display system beingconfigured to operate in a first operating mode when the protectiveshell is a first type of protective shell, and a second operating modewhen the protective shell is a second type of protective shell.
 16. Thewelding helmet of claim 15, wherein the welding display system disablesa first set of functions in the first operating mode, and disables asecond set of functions in the second operating mode, the first set offunctions being different than the second set of functions.
 17. Thewelding helmet of claim 15, wherein the welding display system enables afirst set of functions in the first operating mode, and enables a secondset of functions in the second operating mode, the first set offunctions being different than the second set of functions.
 18. Thewelding helmet of claim 17, wherein the first set of functions includesa superimposition function.
 19. The welding helmet of claim 15, whereinthe welding display system is configured to operate in a third operatingmode when having a first position with respect to the protective shell,and configured to operate in a fourth operating mode when having asecond position with respect to the protective shell.
 20. The weldinghelmet of claim 15, wherein the welding display system is configured toderive a user biometric when positioned within an interior theprotective shell, and configured not to derive the user biometric whenpositioned on an exterior of the protective shell.